Hole in Chassis

Hi All

I was working on the Disco TD5 brakes today and came across a hole on the chassis next to the fuel filter I have had a good look all over and this is the only one there is a lot of surface rust. I think I need to give it a good coat of under seal after I fix it

The only thing you can be sure of is that it will be paper thin for miles around that....

My plan is to cut as much of the rot out and put a big patch over the hole then cover the hole chassis in under seal

Has any one had this problem on a d2 chassis, can you advise on repair tips

as you said clean up to bare metal for a good way before and after and weld patch slightly short than chassis rail as long as is needed for good metal

I am disappointed with this as I was not aware there was a problem with the d2 chassis
I had the wheel off in July and there was no warning signs the chassis had a hole

It is a known problem try doing a search and you will see that yours is not too bad compared to some out there.

I was speaking to guy whose business is swapping lr chassis. He has started doing some disco 2 chassis:-(

We get a lot in to fix, usually much larger areas than that. Once you've fixed it, clean the chassis down and protect it. We tend to get customers wanting protection doing after they get problems as most don't realise D2s can suffer from the dreaded rot worm

Very common as said usually much worse but you really cannot tell until you clean it up.

Loads been in for repair at the local LR place round here

I am not sure what to use waxoyl or a good under seal
What is the best treatment to use and how often will I need to repeat after it's done i.e. every year?

I just bought new rear chassis for mine.mine have been welded and within months need more. they rust from the inside out and patching is a lost cause.the steel is so thin and water traps inside.the new rails are made with 3 and 4mm steel.these replace arms to crossmember once welded on with strenghtening plates will be better than new.

Chassis pictures by cambridgecockney - Photobucket

my chassis as is.
http://s1227.photobucket.com/albums/ee439/cambridgecockney/Land Rover/

Mine I chose to Waxoyl inside and underseal paint outside, some customers just want Waxoyl

Can I put waxoyl in a pressure spray bottle

discochimp said:

Can I put waxoyl in a pressure spray bottle

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yes, best to warm it up first, immerse it in a bucket of hot water or take it inside your house by a rad,
u are better with a Schultz gun, more pressure, so less likely to block as it cools

My father in law used to work for LR and rumour has it that a lot of the early D2 were stored in an area that flooded regularly but not to the point where water got inside the car just around the chassis area so management didnt bother doing anything about it. Not sure if this is urban legend or not but it is a common issue with D2

i would of cleaned/cut a bigger area up if it was me! then fired loads of waxoyl and old sump oil down the chassis both ways as you would of had a bigger hole to work with, then welded the patch in

discodrivercumbria said:

i would of cleaned/cut a bigger area up if it was me! then fired loads of waxoyl and old sump oil down the chassis both ways as you would of had a bigger hole to work with, then welded the patch in

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I don't think I would go anywhere near the chassis with waxoyl/oil before welding,big risk of fire

HenryD said:

I don't think I would go anywhere near the chassis with waxoyl/oil before welding,big risk of fire

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not if you are careful, read my reply, fire it down the chassis!!! when i did my old 300tdi a few years ago i welded it with oxy acet, you were always burning your self, car sort of setting on fire, all the old underseal etc, part of restoration proccess, you can weld rust to rust better with gas!! problem is nobody can gas weld these days,